Electrical box mounting structure preventive of water ingress

ABSTRACT

An electrical unit mounting assembly, having a top, bottom, back and front, and including a partial enclosure, made of insulating material, defining a cavity having a mouth at its front and defining a through-hole leading to the cavity, at its back and a panel extending outwardly from the mouth, for at least 4 cm and having a front surface. In greater detail, the assembly is oriented in an upright manner so that its top is topmost, the through-hole is constructed so that liquid cannot be driven by gravity from inside the cavity, through the through-hole and wherein the front surface of the panel includes raised surfaces defining down channels to prevent a foreign surface from blocking liquid-flow down the down-channels.

RELATED APPLICATIONS

This application is a continuation of application Ser. Nos. 15/900,113 and 15/900,152, both filed Feb. 20, 2018, and both of which claim benefit of provisional patent application U.S. Ser. No. 62/630,379 filed on Feb. 14, 2018, all of which are incorporated by reference as if fully set forth herein.

BACKGROUND

A modern building structure is constructed with an exterior cladding, or primary weather barrier, that provides a first line of defense against the elements and also provides a good appearance for the building structure. Interior to and generally supporting the exterior cladding there is a building frame, typically made of dimensioned lumber (longitudinal elements) mechanically attached together, with sheets of plywood or particle board mechanically attached to the exterior side of these longitudinal elements. The dimensioned lumber may go by industry standard terminology of 2 by 4 s, 2 by 6 s, 2 by 8 s, or even wider elements, depending on the load that must be born, and other factors. Wall board is typically mechanically fastened to the interior side of the longitudinal elements, thereby defining a “wall cavity” between the exterior sheathing and the interior wall board. A secondary weather barrier, that is generally water resistant and is typically made of polymer sheeting, such as Tyvek®, or building paper, is mechanically attached to the building frame. These sheets are generally arranged as shingles are, with each upper piece of sheeting overlapping on the outside of the sheeting immediately below. With this arrangement water does not have any chance of penetrating through to the wall cavity of the building as it flows downward.

A weakness in this scheme is created by electrical receptacles and light fixtures, for example for an exterior electrical junction box, which must go through the exterior cladding and the secondary weather barrier. The general scheme for these (until recently) has been to caulk around them to create a seal against the exterior cladding. This is ineffective, however, as cycles of thermal expansion over the years, and the assault of the elements can weaken the seal, leading to water penetrating into the wall cavity. More recently, a line of products, have been introduced, with a shell defining a cavity and a brim, stretching out from a position to the rear of the front of the shell. These are installed, over the electrical junction boxes, with tape or mechanical attachment. Unfortunately, the portion of the shell extending out from the brim location may not protrude out far enough (or may protrude too far) from the brim to be flush with the edge of the exterior cladding, which differs in thickness from job to job. An installation flush with the exterior surface is desirable for appearance and ease of use of an outlet. Also, water that enters the cavity may work its way between the shell extension and the electrical junction box or to the rear of the electrical junction box and exit through the holes in the electrical junction box that accommodate the electrical wires to the electrical receptacle, thereby entering the wall cavity and potentially causing water damage. Also, it is possible that in places the inner surface of the exterior cladding will rest against the secondary weather barrier and the brim. In this case, water may become trapped and instead of flowing downward sit and cause decay and potential mold growth on the interior of the exterior cladding. Finally, the electrical junction box typically requires a further bracket, or fasteners, for secure attachment to the building frame.

SUMMARY

The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the embodiments are directed to other improvements.

In a first separate aspect, the present invention may take the form of a method of providing an electrical unit, on the exterior of a structure having a frame of longitudinal elements, supporting a secondary weather barrier, and having a primary weather barrier that has an exterior surface. The method utilizes an electrical unit mounting assembly having a partial enclosure defining a cavity having a mouth, and having a panel extending outwardly from the mouth and having a front surface, that has a bottom, the assembly further defining a through-hole, opposed to the mouth. In the method, after the frame has been built, but before the primary weather barrier has been installed, the panel, and thereby the mounting assembly, is attached to the frame, so that the partial enclosure extends forward from the panel. Then the secondary weather barrier is formed on the frame, the secondary weather barrier being formed of sheets of liquid impermeable material, and in the forming of the secondary weather barrier a first sheet of liquid impermeable material is placed so that it extends from above, over a top portion of the panel, and a second sheet of liquid impermeable material is placed so that a bottom portion of the panel extends over a top portion of the second sheet of liquid impermeable material. Continuing, an insulated wire is passed through the through-hole defined by the base portion and is electrically connected to the electrical unit so as to supply electricity to the electrical unit, and the electrical unit is fit into the mounting assembly cavity. Then, the primary weather barrier is installed, leaving a through-hole in it, to accommodate the partial enclosure. In greater detail, the through-hole is constructed so that liquid cannot be driven by gravity to flow out of the cavity through the through-hole, and the front surface of the panel is formed with raised elements that define a set of down channels between the raised elements, the raised elements preventing the primary weather barrier from touching the set of down-channels and thereby blocking water flow down the front surface of the panel, so that any water that enters the cavity will flow out again through the mouth, and any water in the down channels will flow to the bottom of the panel.

In a second separate aspect, the present invention may take the form of an electrical unit mounting assembly, having a top, bottom, back and front, and including a partial enclosure, made of insulating material, defining a cavity having a mouth at its front and defining a through-hole leading to the cavity, at its back and a panel extending outwardly from the mouth, for at least 4 cm and having a front surface. In greater detail, the assembly is oriented in an upright manner so that its top is topmost, the through-hole is constructed so that liquid cannot be driven by gravity from inside the cavity, through the through-hole and wherein the front surface of the panel includes raised surfaces defining down channels to prevent a foreign surface from blocking liquid-flow down the down-channels.

In a third separate aspect, the present invention may take the form of an exterior wall having an outer surface, and comprising a frame, made of longitudinal structural elements, joined together. A secondary weather barrier is mounted on the frame and a primary weather barrier stands outwardly of the secondary weather barrier and has an outer surface that is also the outer surface of the exterior wall. Also, an electrical unit mounting assembly, includes an enclosure defining a cavity having a mouth, and has a panel extending outwardly from the mouth and has a front surface, that has a bottom, and which also defines a through-hole, opposed to the mouth. The panel is joined to at least one of the longitudinal structural elements and an electrical unit set into the cavity. Additionally, insulated electrical wires passing through through-holes in the set of walls of the base, and electrically connected to the electrical unit, and supplying electricity to the electrical unit. In greater detail, the secondary weather barrier comprises sheets of liquid impermeable material, attached to the frame, including a top sheet, and a bottom sheet, and wherein each sheet, other than the bottom sheet, overlaps a sheet beneath it and each sheet, other than the top sheet, is overlapped by a sheet above it and wherein the panel is overlapped by a sheet of material above it and overlaps a sheet of material below it. Finally, the through-hole is constructed so that liquid cannot be driven by gravity to flow out of the cavity through the through-hole, and wherein the front surface of the panel is formed with raised elements that define a set of down channels between the raised elements, the raised elements preventing the primary weather barrier from touching the set of down-channels and thereby blocking water flow down the front surface of the panel, so that any water that enters the cavity will flow out again through the mouth, and any water in the down channels will flow to the bottom of the secondary weather barrier.

In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments are illustrated in the referenced drawings. It is intended that the embodiments and FIGS. disclosed herein are considered illustrative rather than restrictive.

FIG. 1 is an isometric top-front view of an embodiment of an electrical receptacle mounting assembly, according to the present invention.

FIG. 2 is an isometric top-rear view of the electrical receptacle mounting assembly of FIG. 1.

FIG. 3 is an enlarged sectional view of a portion of the electrical receptacle mounting assembly of FIG. 1 along view line 3-3 of FIG. 1 with an alternate position of the front face of telescoping extension 14 shown in dashed line.

FIG. 4 is an exploded isometric view of the electrical receptacle mounting assembly of FIG. 1.

FIG. 5 is an exploded isometric view of the electrical receptacle mounting assembly of FIG. 1, shown during a step in the installation of the assembly into a wall frame, with obscured portions of a longitudinal support in dashed lines.

FIG. 6 is an isometric view of the electrical receptacle mounting assembly of FIG. 1, shown during a step in the installation of the assembly into a wall frame, with obscured portions of a framing longitudinal support in dashed lines.

FIG. 7 is an isometric view of the electrical receptacle mounting assembly of FIG. 1, during a step in the installation of the assembly into a wall frame, with a secondary weather barrier, and with obscured portions of the assembly and a portion of a lower sheet of weather barrier shown in dashed line.

FIG. 8 is an isometric view of the electrical receptacle mounting assembly of FIG. 1, installed into a finished wall and hosting an electrical receptacle.

FIG. 9 is an isometric top-front view of the front of an embodiment of an electrical light fixture mounting assembly, according to the present invention.

FIG. 10 is an isometric top-rear view of the face of the electrical light fixture mounting assembly of FIG. 9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Definition

As used in this application, an “electrical unit” may be either an electrical receptacle (typically having 2, 4, 6 or 8 individual sockets), or an electrical fixture, for example a lighting fixture.

Description

Referring to FIGS. 1-4, in the attached set of FIGS., an electrical receptacle mounting assembly 10 includes a base unit 12 and a telescoping extension 14. FIGS. 3 and 4 show an adjustment bolt 16 that includes a threaded portion that extends through a threaded opening 18 and is rotatably attached at an anchor 20 at the rear of base unit 12, so that an installer may adjust the distance that extension 14 extends out of base unit by rotating bolt 16, with a manual or an electric screw driver. Skilled persons will recognize that this design can be rearranged so that bolt 16 is in threaded engagement to base unit 12, and rotatably engaged (but fixed in terms of position along the length of bolt 16) to telescoping extension 14, to achieve the same effect.

Base unit 12 consists of two general portions: partial enclosure 22 and panel 28. Partial enclosure 22 defines a base unit cavity 24 that accepts extension 14. Although enclosure 22 has two punch-outs 26 (see FIG. 2) that may be removed to create through-holes 27 (FIG. 3) for permitting an electrician to extend wires into cavity 24 and extension 14, punch-outs 26 are at the top of enclosure 22. Unlike otherwise similar assemblies, there are no through-holes at the bottom. Accordingly, any water that enters cavity 24 must exit through the front.

Skilled persons will readily recognize that partial enclosure 22 includes outer walls 23 (FIGS. 3 and 4) and an interior frame 25 (FIGS. 1, 3 and 4), between which the structure of extension 14 largely fits.

Panel 28 has a set of protruding ribs 30, that prevent any portion of the primary weather barrier 54 (FIG. 8) from blocking water flow through a set of channels 32, defined by ribs 30. A set of guide dimples 34 provide spaced apart places for nailing or screwing base unit 12 to the framing of the structure.

Referring to FIGS. 5 and 6, to use electrical receptacle mounting assembly 10, a sheet 36 (“bib sheet”), of the material used for the secondary weather barrier is installed in a location directly beneath a desired location for an electrical receptacle, and a through-hole 38 is created through an underlying piece of sheathing 42, to accommodate enclosure 22. Enclosure 22 is fitted through through-hole 38 and unit 12 is nailed or screwed to a framing longitudinal support 44 at dimples 34, so that the lower portion of panel 28 (FIGS. 1, 3 and 4) extends over bib sheet 36. Then (FIG. 7), an additional sheet 40 of the secondary weather barrier is added, so that it overlaps the top part of the front of panel 28 and of sheet 36. As shown, a hole or a notch is cut out to accommodate an eventual protrusion of telescoping extension 14. Secondary weather barrier elements 40 (FIG. 7) and 36 are water resistant, typically made of polymer sheeting such as Tyvek®, comprising high-density polyethylene fibers. Alternatively, polypropylene sheeting or asphalt saturated building paper is used.

At this point, or earlier, prior to wallboard being attached to the interior side of support 44 a pair of wires 50 (FIG. 3) are pulled through holes 27 (FIG. 3), and (referring to FIG. 8) an electrical receptacle 60, typically an outlet, is installed into cavity 24, connected to wires 50, and retained with mechanical screws, installed in a pair of threaded holes 52 (FIGS. 1 and 4). Finally, the primary weather barrier 54 is installed and bolt 16 (FIGS. 3 and 4) is rotated to bring extension 14 to the level of the outside surface of barrier 54.

The unit 10 is now installed, together with unit 60, and the wall cavity 56 is entirely protected from water ingress.

Referring to FIG. 8, an exterior wall having an outer surface has now been created, that includes a frame, made of longitudinal structural elements 44 joined together, and a secondary weather barrier made of sheets 40 and 36 (FIG. 7). Sheets 40 and 36 and others are not shown, but are mounted on the sheathing 42 which are themselves supported by the frame 44. A primary weather barrier 54, also known as cladding, is outward of the secondary weather barrier, and has an outer surface that is also the outer surface of the exterior wall. Electrical receptacle mounting assembly 10 includes a base 12. The base has two portions: enclosure 22 and panel 28. Enclosure 22 defines a cavity 24 having a mouth, a through-hole 27, opposed to the mouth, leading to the cavity 24. Panel 28 extends outwardly from the mouth, in the space 62 (not shown) between underlying sheathing 42 and primary weather barrier 54, parallel to the secondary weather barrier 40 (FIG. 7). The panel is joined to at least one of the longitudinal structural elements 44 and is joined to the secondary weather barrier 40, so that base unit 12 forms an additional secondary weather barrier. Electrical mounting unit assembly 10 further includes telescoping extension 14 having a front surface, and wherein extension 14 is an extension set in place so that the front surface is flush with the outer surface of the primary weather barrier 54. Electrical unit 60 is set into the base unit cavity 24 and insulated electrical wires 50 pass through through-holes 27 of enclosure 22. Thus, electrical unit 60 is electrically connected and may now be powered.

FIGS. 9 and 10 show an embodiment of an electrical light fixture mounting assembly 10′, having a base unit 12′ and an enclosure 22′ hosting a telescoping tubular extension 14′. As noted in the definition section, an “electrical unit” may be either a receptacle or a fixture. Assembly 10′ is of a general form most typically used for the junction of a light fixture with a source of electricity. Although assembly 10 is most typically used for mounting an electrical fixture, it is not limited to this role, but could be used to mount some type of a fixture, as well.

A bolt (not shown), similar to bolt 16 of assembly 10 held inside bolt cavity 17′ and engaged to base unit 12′ in the same manner as bolt 16 permits speedy adjustment of the level of projection of extension 14′ from assembly 10′. Tubular extension 14′ and enclosure 22′ are shaped in more of a piecewise oval manner, to accommodate a matching electrical receptacle or light fixture (not shown).

Through-holes 27 (FIG. 3), created after the removal of punch-outs 26 (FIG. 2), prevent water flow out of enclosure cavity 24 into wall cavity 56, where it could potentially do a great deal of harm. In an alternative preferred embodiment, additional through-holes are provided, beneath through-holes 27, but also having a downward angle (if viewed from the outside of cavity 24 to the inside), similar to the disposition of through-holes 27. Assembly 10 may be generally formed of a polymeric material, such as polyvinyl chloride, polyamide or a similar material, and telescoping extension 14 may be injection molded. Because assembly 10 is not vertically symmetric, as it is designed to prevent water from flowing out the back of enclosure 22 into a wall cavity, it is important that it bear indicia 58 (FIG. 1), indicating the “up” side, as shown.

In alternative embodiments, instead of ribs 30 (FIGS 1 and 4), other forms of raised areas are used to define down channels 32 (FIGS. 1, 4, and 5), for example a sequence of raised dots or oval shapes. In another embodiment, down channels 32 are not linear, as shown, but are wavy or split apart and joined together. Any method of preventing the interior surface (not shown) of the cladding 54 (FIG. 8) from blocking the downflow of water by resting against a portion of the surface of panel 28 (FIGS. 1, 3, and 4)falls within the scope of one separate aspect of the invention.

Also, in an alternative embodiment, telescoping extension 14 is omitted, and may be replaced with an extension of enclosure 22, extending forward of panel 28. In a preferred embodiment a set of mounting assemblies, similar to mounting assembly 10, but without telescoping extension 14 are provided, with extensions of enclosure 22, projecting forward by differing lengths from panel 28. An installer chooses the assembly having an extension that comes closest to matching the prospective location of the outside surface of the primary weather barrier.

The method, device and constructed wall, according to embodiments of the present invention represent an important paradigm shift over existing methods, which used the primary weather barrier or a combination of the primary and secondary weather barriers to prevent water entry into the wall cavity. In the above-described embodiments, the stand taken against water ingress is unequivocally positioned at the secondary weather barrier, thereby permitting a greater freedom of implantation at the primary weather barrier. Moreover, the water seal is not dependent on elements that show wear over time, such as caulking or tape, but rather depend on solid elements that have wear lives on the order of several decades. Given the over one-hundred million houses in the United States, an apparatus and method saving them from the damage caused by water ingress into the wall cavities, can be expected to save building owners many billions of dollars per year.

While a number of exemplary aspects and embodiments have been discussed above, those possessed of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope. 

The invention claimed is:
 1. An electrical unit mounting assembly, having a top, bottom, back and front, and comprising: a partial enclosure, made of insulating material, defining a cavity having a mouth at its front and defining a single set of through-holes leading to said cavity, at its back; a panel extending outwardly from said mouth, for at least 4 cm and having a front surface; and wherein, when said assembly is oriented in an upright manner so that its top is topmost, said single set of through-holes is constructed so that liquid cannot be driven by gravity from inside said cavity, through any one of said single set of through-holes and wherein said front surface of said panel includes raised surfaces defining down channels to prevent a foreign surface from blocking liquid-flow down said down-channels.
 2. The electrical unit mounting assembly of claim 1, wherein said cavity is in the form of a rectangle, covering an area of between 15 cm² and 120 cm².
 3. The electrical unit mounting assembly of claim 2, wherein said rectangle has rounded sides.
 4. The electrical unit mounting assembly of claim 1, wherein said panel bears an indicator on its front surface indicating a preferred vertical orientation.
 5. The electrical unit mounting assembly of claim 1, further including a telescoping extension fit into said partial enclosure.
 6. The electrical unit mounting assembly of claim 5, wherein said partial enclosure includes an inner frame and a set of outer walls, and said telescoping extension is fitted into said cavity, between said inner frame and said outer wall.
 7. The electrical unit mounting assembly of claim 6, further including a single adjustment bolt, having a longitudinal segment that is rotatably engaged to a first one of said base portion and said extension, and having a threaded portion being in threaded engagement to a second one of said base portion and said extension, so that rotation of said adjustment bolt causes said extension to move in a telescoping manner relative to said cavity. 